Reload assembly with spent reload indicator

ABSTRACT

A reload assembly is disclosed that includes a proximal body portion having an indicator that is movable from a retracted position to an advanced position to provides a visual indication to a clinician of the state of the reload assembly, i.e., whether the reload assembly is loaded with staples and ready for use or depleted of staples. A tool assembly of the presently disclosed reload assembly may also include a cartridge assembly, an anvil and a drive assembly. In embodiments, one or both of the cartridge assembly, the anvil, and/or the drive assembly may support an illuminating device. In embodiments, the illuminating device, which may be an LED, is adapted to change color when the reload assembly has been fired to provide an indication to a clinician that the reload assembly is spent. Since the illuminating device is illuminated when reload assembly is in both the unused and spent states, the illuminating device also improves visualization during placement and use of the reload assembly.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 15/362,896, filed Nov. 29, 2016, the entire disclosure of which is incorporated by reference herein.

BACKGROUND 1. Technical Description

The present disclosure relates to surgical stapling devices and, more particularly, to reload assemblies for surgical stapling devices having reload indicators that identify the current condition of the reload assembly.

2. Background of Related Art

Surgical stapling devices that include disposable reloads are known in the art. Disposable reloads can be separated from the stapling device and replaced with a fresh or loaded disposable reload to facilitate reuse of a stapling device during a surgical procedure to minimize costs associated with the surgical procedure. After a stapling device is fired and the disposable reload is spent, i.e., the staples have been fired from the reload, the disposable reload is separated from the stapling device and discarded. In order to prevent reuse of a spent reload, reloads typically include a lockout to prevent re-advancement of a drive member of the reload. However, the lockout is not visible to a clinician and thus, the clinician may not be aware the reload is spent until the reload is attached to the stapling device and an attempt is made to fire the stapling device. In addition, during a surgical procedure, a clinician may remove an unused reload from the stapling device to attach a reload of a different size. Although the removed reload may have blood or other tissue on the reload, it is still suitable for use.

It would be desirable to provide a disposable reload including an indicator that provides a clear indication to a clinician of the condition of the reload, i.e., if the reload is fresh or spent.

SUMMARY

In one aspect of the disclosure a reload assembly includes a proximal body portion having a housing defining a window, a drive assembly, and an indicator. The drive assembly is supported within the housing and is movable from a retracted position to an advanced position. The indicator is supported within the housing and is movable from a retracted position to an advanced position in response to movement of the drive assembly from the retracted position to the advanced position. A tool assembly is supported on a distal portion of the proximal body portion. The tool assembly includes first and second jaws, wherein the first jaw supports an anvil and the second jaw supports a cartridge assembly having a plurality of staples. The indicator includes first and second indicia. The first indicium is positioned beneath the window of the housing in the retracted position of the indicator and the second indicium is positioned beneath the window of the housing in the advanced position of the indicator.

In embodiments, the first indicium includes a first color and the second indicium includes a second color different than the first color.

In some embodiments, the first indicium is green and the second indicium is red.

In certain embodiments, the drive assembly includes a distal working portion that is movable through the tool assembly as the drive assembly moves from the retracted position towards the advanced position to eject the plurality of staples from the cartridge assembly.

In embodiments, at least one illuminating device is supported on the tool assembly.

In some embodiments, the illuminating device is supported on at least one of the cartridge assembly, the anvil, and the drive assembly.

In certain embodiments, the illuminating device is a light emitting diode.

In embodiments, the illuminating device is adapted to have a change in state after the drive assembly is moved from the retracted position to the advanced position to eject the plurality of staples from the cartridge assembly.

In some embodiments, the change in state is a change in color.

In certain embodiments, the proximal body portion includes an inner body supported within the housing. The inner body defines an elongated recess and the indicator is movable within the elongated recess from the retracted position to the advanced position.

In embodiments, the indicator includes a body and a cantilevered leg extending proximally of the body. The cantilevered leg is positioned to be engaged by drive assembly as the drive assembly moves from the retracted position towards the advanced position to move the indicator from its retracted position to its advanced position.

In some embodiments, the body of the indicator is semi-cylindrical and is dimensioned to be positioned about the inner body within the elongated recess.

In certain embodiments, the cantilevered leg of the indicator is movable from a deformed state in which the cantilevered leg is positioned to be engaged by the drive assembly to a non-deformed state in which the cantilevered leg of the indicator is spaced from a path of movement of the drive assembly.

In embodiments, the inner body defines an inner wall that is positioned to retain the cantilevered leg of the indicator in the deformed state when the indicator is in the retracted position.

In some embodiments, the inner body defines a slot that is positioned to receive the cantilevered leg of the indicator when the indicator is in the advanced position to allow the cantilevered leg to move to the non-deformed state.

In certain embodiments, the inner wall defines a protrusion and the cantilevered leg defines a concavity. The protrusion is received within the concavity to releasably retain the indicator in the retracted position.

In another aspect of the disclosure, a reload assembly includes a proximal body portion having an inner body and a drive assembly supported within the inner body. The drive assembly has a distal working portion and is movable within the inner body from a retracted position to an advanced position. A tool assembly includes first and second jaws that are movable in relation to each other from an open position to a clamped position. The first jaw supports an anvil and the second jaw supports a cartridge assembly having a plurality of staples. The distal working portion of the drive assembly is movable through the tool assembly to eject the plurality of staples from the cartridge assembly. The tool assembly supports an illuminating device that defines indicia, the indicia being adapted to change from a first state to a second state when the plurality of staples is ejected from the cartridge assembly.

In embodiments, in the first state the indicia is a first color and in the second state the indicia is a second color.

In some embodiments, the illuminating device is supported on at least one of the anvil, the cartridge assembly, and the drive assembly.

In certain embodiments, the illuminating device is supported on a distal portion of at least one of the anvil and the cartridge assembly.

In embodiments, the illuminating device includes a light emitting diode.

In some embodiments, the proximal body portion includes a housing that receives the inner body and an indicator positioned within the housing. The indicator is supported within the housing and is movable from a retracted position to an advanced position in response to movement of the drive assembly from the retracted position to the advanced position. The indicator includes first and second indicium, the first indicium being positioned beneath the window of the housing in the retracted position of the indicator and the second indicium being positioned beneath the window of the housing in the advanced position of the indicator.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the presently disclosed reload assembly for a surgical stapling device are described herein below with reference to the drawings, wherein:

FIG. 1 is a side, perspective view of a surgical stapling device including one embodiment of the presently disclosed reload assembly with a tool assembly in an open position;

FIG. 2 is an enlarged, top, perspective view of the reload assembly shown in FIG. 1;

FIG. 3 is an enlarged view of the indicated area of detail shown in FIG. 2;

FIG. 4 is an enlarged view of the indicated area of detail shown in FIG. 2;

FIG. 5 is an enlarged view of the indicated area of detail shown in FIG. 2;

FIG. 6 is an enlarged, bottom, perspective view of the reload assembly shown in FIG. 1;

FIG. 7 is an enlarged view of the indicated area of detail shown in FIG. 6;

FIG. 8 is an enlarged view of the indicated area of detail shown in FIG. 6;

FIG. 9 is a top view of the reload assembly shown in FIG. 2 with the tool assembly in a clamped position shown in phantom;

FIG. 10 is an exploded view of the reload assembly shown in FIG. 9;

FIG. 11 is an enlarged view of the indicated area of detail shown in FIG. 10 illustrating a top view of an indicator of the reload assembly;

FIG. 12 is a bottom view of the indicator shown in FIG. 11;

FIG. 13 is an enlarged view of the indicated area of detail shown in FIG. 10;

FIG. 14 is a side, perspective view of a proximal portion of the reload assembly shown in FIG. 9 with an outer housing removed and the indicator in a retracted position;

FIG. 15 is a top view of a proximal portion of the reload assembly shown in FIG. 9 with the outer housing shown in phantom and the indicator and drive member in retracted positions;

FIG. 16 is a top view of a proximal portion of the reload assembly shown in FIG. 9 with the outer housing shown in phantom, the drive member a partially advanced position prior to engagement with the indicator, and the indicator in a retracted position;

FIG. 16A is a perspective view of the tool assembly of the reload assembly shown in FIG. 9 in the clamped position;

FIG. 17 is a cross-sectional view taken along section line 17-17 of FIG. 6;

FIG. 18 is a top view of a proximal portion of the reload assembly shown in FIG. 9 with the outer housing shown in phantom, the drive member a partially advanced position engaged with the indicator, and the indicator in an advanced position;

FIG. 19 is a bottom, perspective view of the reload assembly shown in FIG. 9 in the clamped position with the drive member fully advanced;

FIG. 20 is an enlarged view of the indicated area of detail shown in FIG. 19;

FIG. 21 is an enlarged view of the indicated area of detail shown in FIG. 19;

FIG. 22 is a bottom, perspective view of the reload assembly shown in FIG. 19 in the clamped position with the drive member fully advanced;

FIG. 23 is an enlarged view of the indicated area of detail shown in FIG. 22;

FIG. 24 is an enlarged view of the indicated area of detail shown in FIG. 22;

FIG. 25 is a side, perspective view of the reload assembly shown in FIG. 22 after the reload assembly has been fired and detached from the body portion of the stapling device shown in FIG. 1;

FIG. 26 is an enlarged view of the indicated area of detail shown in FIG. 25; and

FIG. 27 is an enlarged view of the indicated area of detail shown in FIG. 25;

DETAILED DESCRIPTION OF EMBODIMENTS

The presently disclosed reload assembly, in association with a surgical stapling device, will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. In this description, the term “proximal” is used generally to refer to that portion of the device that is closer to a clinician, while the term “distal” is used generally to refer to that portion of the device that is farther from the clinician. In addition, the term “endoscopic” is used generally to refer to endoscopic, laparoscopic, arthroscopic, and any other surgical procedure performed through a small incision or a cannula inserted into a patient's body. Finally, the term clinician is used generally to refer to medical personnel including doctors, nurses, and support personnel.

The reload assembly includes a proximal body portion that includes an indicator that is movable from a retracted position to an advanced position. As described in detail below, in the retracted position, the indicator provides a visual indication to a clinician that the reload assembly is loaded with staples and ready for use, i.e., the reload assembly is fresh, and in the advanced position, the indicator provides a visual indication to a clinician that the reload assembly is depleted of staples, i.e., the reload assembly spent. In embodiments, the tool assembly of the presently disclosed reload assembly includes a cartridge assembly and an anvil. As described in detail below, one or both of the cartridge assembly and anvil may include an illuminating device that is adapted to change color when the reload assembly has been fired to provide an indication to a clinician that the reload assembly is spent. Since the illuminating device is illuminated when reload assembly is in both the fresh and spent states, the illuminating device also improves visualization during placement and use of the reload assembly within a body cavity.

FIG. 1 illustrates a surgical stapling device 10 including a handle or actuator assembly 12, an adaptor assembly 14, and a reload assembly 100. The actuator assembly 12 includes a stationary grip 16, actuation buttons 18, and a battery pack 20 secured to the stationary grip 16. The adaptor assembly 14 includes a proximal portion that is releasably coupled to the actuator assembly 12 and a distal portion that supports the reload assembly 100. U.S. Patent No. 2014/0110453 ('453 publication), hereby incorporated by reference herein in its entirety, discloses an electrically powered surgical stapling device including an actuator assembly 12 and an adaptor assembly 14. Although the present disclosure illustrates the surgical stapling device 10 as being electrically powered, it is envisioned that the surgical stapling device 10 can be manually actuated. U.S. Pat. No. 5,865,361 (the '361 Patent) and U.S. Pat. No. 7,143,924 (the '924 Patent), hereby incorporated by reference herein in their entirety, disclose known manually powered surgical stapling devices. It is also envisioned that the reload can be configured for use in a robotic surgical system.

Referring to FIGS. 2-8, the reload assembly 100 includes a proximal body portion 102, a tool assembly 104, and coupling assembly 106 that pivotally secures the tool assembly 104 to the proximal body portion 102. A suitable coupling assembly 106 is described in the '361 Patent and is not described in further detail herein. Alternatively, the tool assembly 104 can be fixedly secured to a distal portion of the proximal body portion 102 such that articulation of the tool assembly 104 in relation to the proximal body portion 102 is not permitted. The tool assembly 104 includes a pair of jaws, wherein one of the jaws includes or supports a cartridge assembly 108 and the other of the pair of jaws includes or supports an anvil 110. The cartridge assembly 108 and the anvil 110 are pivotal in relation to each other between spaced and clamped positions as is known in the art to clamp tissue between the jaws. See, for example, the '361 Patent.

The proximal body portion 102 of the reload assembly 100 includes an inner body 116 that is received within a cylindrical housing 118 (FIG. 10). The inner body 116 has a proximal end that extends from the cylindrical housing 118 and includes nubs 121 adapted to releasably engage a distal portion of the adapter assembly 14 (FIG. 1) in a bayonet-type fashion as described in the '361 Patent. The distal end of the inner body 116 is connected to the coupling assembly 106 to secure the tool assembly 104 to the proximal body portion 102 of the reload assembly 100. The housing 118 of the proximal body portion 102 includes at least one window 120 a, 120 b to facilitate visualization of an indicator 122 positioned within the cylindrical housing 118. In embodiments, the housing 118 defines a window 120 a (FIG. 3) on a first side of the housing 118 and a window 120 b (FIG. 7) on a second side of the housing 118 to facilitate visualization of the indicator 122 from both sides of the housing 118. Although the windows 120 a, 120 b are shown to be oval-shaped, it is envisioned that the windows 120 a, 120 b may assume any of a variety of different configurations that allow a clinician to visualize the indicator 122.

The tool assembly 104 may support one or more illuminating devices 124 a-c to improve visualization while the tool assembly 104 is maneuvered endoscopically past tissue to a surgical site. The illuminating device(s) 124 a-c may be electrically connected to the battery pack 20 (FIG. 1) of the actuator assembly 12. Alternatively, a separate power source can be provided in the surgical stapling device 10 or reload assembly 100 for the illuminating device 124 a-c. In embodiments, the illuminating device 124 a can be positioned on a distal portion of the anvil 108 (FIG. 5), on a portion of a drive assembly 130 (FIG. 4) of the reload assembly 100, and/or on a distal portion of the cartridge assembly (FIG. 8). In embodiments, the illuminating device 124 a-c can be a light emitting diode (LED) although other types of illuminating devices are envisioned.

In some embodiments, the illuminating device(s) 124 a-c is adapted to change state after the reload assembly 100 has been fired to provide a visual indication to a clinician about the condition of the reload assembly 100, i.e., whether the reload assembly 100 is fresh or spent. For example, the illuminating device(s) 124 a-c may initially emit a green light after the reload assembly 100 is attached to the adapter assembly 14 but prior to use. After the reload assembly 100 is fired, the illuminating device 124 a-c may change state to emit a red light. Alternately, rather than change color, the illuminating device 124 a-c may include indicia that changes in configuration upon firing. For example, the illuminating device 124 a-c may define indicia that changes from “fresh” to “spent” upon firing of the reload assembly 100. Alternately, the use of other colors, indicia configurations, and types of indicia are envisioned.

Referring to FIGS. 9 and 10, the proximal body portion 102 includes the inner body 116 (FIG. 9), the drive assembly 130, the indicator 122, the housing 118, an articulation link 136, and a drive assembly lockout 138. For a detailed description of the articulation link 136, the lockout 138, and the operation of both, see the '924 Patent. The inner body 116 is formed from an upper half-section 116 a and a lower half-section 116 b that are secured together using interlocking structures, ultrasonic welding or the like. The upper and lower half-sections 116 a, 116 b include an outer surface that defines an elongated recess 140. The drive assembly 130 includes a proximal connector 132 that is adapted to releasably couple the drive assembly 130 to a control rod ('361 Patent) or drive shaft ('453 Publication) (not shown) of the adapter assembly 14. The drive assembly 130 also includes a distal working portion 134 that is positioned to translate through the tool assembly 104 to eject staples from the cartridge assembly. In embodiments, the working portion 134 of the drive assembly 130 includes a knife 134 a for transecting tissue clamped between the anvil and cartridge assemblies.

Referring also to FIGS. 11-13, the indicator 122 is formed of a resilient material and includes a semi-cylindrical body 150 and a proximally extending cantilevered leg 152. The body 150 includes indicia including first indicium 150 a and second indicium 150 b. The first and second indicium 150 a, 150 b may be colors, e.g., red and green, or include symbols or lettering, e.g., “fresh” and “spent”. In embodiments, the semi-cylindrical body 150 defines an arc of greater than 180 degrees and is movable within the elongated recess 140 of the inner body 116 from a retracted position to an advanced position. Alternately, other body configurations are envisioned. The cantilevered leg 152 extends radially inwardly from the body 150 of the indicator 122 into a cavity 154 defined by the body 150. In embodiments, the cantilevered leg 152 extends proximally from a spine 156 (FIG. 12) defined along an inner surface 150 a (FIG. 12) of the body 150 of the indicator 122. The spine 156 is slidably received within an elongated slot 160 (FIG. 13) defined in the inner body 116 to prevent the indicator 122 from rotating about the inner body 116. In the retracted position of the indicator 122, the cantilevered leg 152 is supported on an inner wall 170 of the inner body 116 in an inwardly deformed state in a path of movement of the drive assembly 130 and proximally of the elongated slot 160 of the inner body 116.

The inner wall 170 of the inner body 116 defines a protrusion 172 (FIG. 13) and the cantilevered leg 152 of the indicator 122 defines a concavity 174. In the retracted position of the indicator 122, the protrusion 172 is received within the concavity 174 to releasably retain the indicator 122 in its retracted position until the indicator 122 is engaged by the drive assembly 130 to advance the indicator 122 towards its advanced position.

Referring to FIGS. 14 and 15, when the reload assembly 100 is fresh and the drive assembly 130 is in its fully retracted position, the proximal connector 132 is spaced proximally of the proximal end of the cantilevered leg 152 and the indicator 122 is in its fully retracted position with the first indicium 150 a positioned beneath the windows 120 a, 120 b of the housing 118. In this position, the cantilevered leg 152 is deformed inwardly and rests on the inner wall 170 of the inner body 116, and the protrusion 172 on the inner wall 170 of the inner body 116 is received within the concavity 174 of the cantilevered leg 152 to releasably retain the indicator 122 in its retracted position. In addition, the working end 134 of the drive assembly 130 is positioned in a proximal portion of the tool assembly 104 such that the anvil 110 and cartridge assembly 108 are in a spaced position (FIG. 2).

It is noted that the proximal connector is positioned proximally of the proximal end of the cantilevered leg 152 a distance “X” (FIG. 15). The distance “X” is selected to allow the drive assembly 130 to move the tool assembly 104 to the clamped position without advancing the indicator 122. Thus, if the tool assembly 104 of the reload assembly 100 is moved between the spaced and clamped positions but has not been fired, the reload assembly will still provide an indication to a clinician that the reload assembly 100 is fresh if it is subsequently removed from the stapling device 10 prior to firing.

Referring to FIG. 16, when the drive assembly 130 is advanced in the direction indicated by arrow “A” to move the tool assembly 104 to the clamped position, the drive assembly 130 including the connector 132 are moved distally within the inner body 116 of the reload assembly 100 such that the connector 132 approaches the proximal end of the indicator 122. As the drive assembly 130 moves distally, the working portion 134 engages the cartridge assembly 108 and anvil 110 to move the jaws to the clamped position (FIG. 16A).

As shown in FIG. 17, the spine 156 of the indicator 122 is positioned within the elongated slot 160 defined in the inner body 116 of the proximal body portion 102 of the reload assembly 100. This prevents rotation of the indicator 122 about the inner body 116 of the proximal body portion 102 to maintain alignment of the cantilevered leg 152 and the elongated slot 160.

Referring to FIG. 18, when the reload assembly 100 is fired by actuating the actuator assembly 12 (FIG. 1) as is known in the art, the drive assembly 130 moves into engagement with the proximal end of the cantilevered leg 152 to advance the indicator 122 distally to its advanced position. When the indicator 122 reaches its advanced position, a distal end of the indicator 122 engages a wall or first stop surface 180 defining a distal end of the slot 160 to prevent further distal movement of the indicator 122. When this occurs, the cantilevered leg 152, which is now positioned above the slot 160 in the inner body 116, springs outwardly in the direction indicated by arrow “B” into the slot 160 to its non-deformed state. In its non-deformed state, the cantilevered leg 152 is positioned outwardly of the path of movement of the drive assembly 130 and is aligned with a wall or second stop surface 182 defining a proximal end of the slot 160. The second stop surface 182 prevents proximal movement of the indicator 122. Thus, the indicator 122 is prevented from moving both proximally and distally and is locked out. In the locked out position, the second indicium 150 b is positioned beneath the windows 120 a, 120 b.

Referring also to FIGS. 19-24, when the cantilevered leg 152 springs outwardly into the slot 160, the drive assembly 130 is free to continue to move in the direction indicated by arrow “A” (FIG. 18) past the cantilevered leg 152 to its fully advanced position (FIG. 22) to eject the remaining staples from the cartridge assembly 108.

Referring to FIGS. 25-27, when the drive assembly 130 is retracted, the drive assembly 130 including the proximal connector 132 can pass by the cantilevered leg 152 of the indicator 122 which is positioned within the slot 160. As described above, the indicator 122 is locked out with the second indicium 150 b positioned beneath the windows 120 a, 120 b of the housing 118 to provide a clear indication to a clinician that the reload assembly 100 is spent. In addition as described above, the illuminating device 124 a-c can change state to provide further visualization to a clinician that the reload assembly 100 is spent. At this point, the reload assembly 100 can be removed from the surgical stapling device 10 and discarded.

Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. It is envisioned that the elements and features illustrated or described in connection with one exemplary embodiment may be combined with the elements and features of another without departing from the scope of the present disclosure. As well, one skilled in the art will appreciate further features and advantages of the disclosure based on the above-described embodiments. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. 

What is claimed is:
 1. A reload assembly comprising: a proximal body portion including a housing, a drive assembly, and an indicator, the housing defining a window, the drive assembly supported within the housing and being movable from a retracted position to an advanced position, the indicator being supported within the housing and being movable from a retracted position to an advanced position in response to movement of the drive assembly from the retracted position to the advanced position; and a tool assembly supported on a distal portion of the proximal body portion, the tool assembly including first and second jaws, the first jaw supporting an anvil and the second jaw supporting a cartridge assembly having a plurality of staples; wherein the indicator includes first and second indicia, the first indicia being positioned beneath the window of the housing in the retracted position of the indicator and the second indicia being positioned beneath the window of the housing in the advanced position of the indicator. 